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CHAPTER 1
INTRODUCTION
Portable Jib Crane is a small lifting, and material handling equipment used in
engineering workshops as well as in godowns & ware houses. Jib Cranes can be used for
lifting of different type of material in the segments where frequent lifting & handling of
material activity is required. The purpose of these devices is simply to help workers move
objects weighing from 50kg to 400kg from one point to another. Portable Jib Cranes is
electrically powered for lifting operation, according to the need. Special types of Jib
Cranes are also used in positioning the cameras in shootings.
The two degrees of freedom in the horizontal plane are provided by the wheels
provided, while the third, vertical degree of freedom is provided by a hoist.
Because of low cost and versatile use, there is a very good application for the jib
cranes. . The designing and fabrication of this portable jib crane uses application of
mechanics of solids ,manufacturing technology and various subjects of mechanical
engineering.
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CHAPTER 2
LITERATURE REVIEW
Jib Cranes are industrial machines which mostly uses for materials movements in
construction of buildings, production halls, assembly lines, storage areas, and power
plants. The design features of jib crane vary widely according to their major operational
and manufacturing specifications such as: crane structure according to motion, weight
and type of the load, crane location, geometric features, and environmental conditions.
However, a review of the available literature tells that technical design of jib cranes are
highly saturated and standardized in many industrial companies and organizations
independent of the jib crane type.
Consideration of the available technology that is mainly based on the accumulated
previous experience is important for better performance, higher safety and more reliable
designs. It is well known that generic features of jib crane components are similar for
various different types of cranes. Since the jib crane design procedures are highly
standardized with these components, main effort and time spent in jib crane design
projects are mostly for interpretation and implementation of the available design.
In the initial stage the project overview and scope of project is analyzed. Further
on the literature based on the current design is reviewed.
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CHAPTER 3
TYPES OF JIB CRANES
Jib crane consists of an inclined member supported by a rope or any other type of
structural member attached to a vertical mast or frame. Load is usually suspended from
the outer end of this inclined mast. The outreach of the jib may be fixed or variable. The
cranes as a whole may be either, fixed or moveable. Various sub-classifications of these
cranes are possible.
Lifting capacity of such cranes may vary from 1/2 ton to 200 ton and outreach
from a few meter to 50 meter. Such cranes find various applications in port area,
construction site, and other outdoor works.
For handling general cargo, lifting capacities are usually 1.5 ton to 5 ton with
maximum outreach of 30 meter. Jib Cranes provided with grabbing facilities have usually
a capacity ranging from 3 to 20 tons operating 50 to 100 cycles per hour. Lifting heights
may be 30 meters or more.
Jib crane used in ship yards for lifting heavy machinery and equipment, weighing
100 to 300 tons, are usually mounted on pontoons. Frequently these cranes are provided
with two main hoisting winches which can be employed singly or together to lift a load.
For handling light loads these cranes may have auxiliary arrangement.
Depending on the use, jib cranes are classified into a number of varieties,
primarily on the basis of their mountings. These are:
1. Hand Operated Scotch Derrick Type
2. Wall Mounted Jib crane
3. Portal / Semi-portal cranes of different varieties-Wharf cranes
4. Mobile jib cranes consisting of truck mounted and crawler mounted cranes
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3.1 Scotch Derrick Type / Wall Cranes:
Figure3.1: scotch derrick type crane
Wall cranes are used in ware houses for handling light weight and when there is
little or no wharf between them and the water front. Slewing or rotational motion of the
crane is possible within restricted angle and the motion is slow. Hoisting and lifting
speeds are comparable to those of wharf cranes. In some modified version these cranes
can have travelling speed along the wall.
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Figure 3.2: small model of Wall Crane
3.2Wharf Cranes:
These are used in shipyard and port for handling unit and bulk load. These are
usually self-propelled balanced level luffing type with full circle slewing motion facility.
Wharf cranes may be of different types, depending on the type of structure on which it is
mounted. The choice of structure for mounting depends on site condition.
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Figure3.3: Wharf Cranes
The principal types of wharf cranes are:
High pedestal
Full Portal
Semi-portal
3.3 Portal Cranes:
Portal crane is a fixed or revolving type jib crane mounted on a portal frame fixed
in location or arranged to travel along a fixed track of rails at the same level. The portal
frame consists essentially of horizontal girders connected at both ends to vertical or
inclined member’s having equal lengths.
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3.4 Semi portal Crane:
Semi portal crane is a fixed or revolving type jib crane mounted on a semi portal
frame fixed in location or arranged to travel along a fixed track or rails at different levels.
The semi portal frame essentially consists of horizontal girders connected at both ends to
vertical or inclined members which constitute a shorter side and a longer side. The
shorter members may consist only of the trolley running along the elevated rail.
Figure3.4: Semi portal Crane
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3.5 Mobile crane:
Mobile Crane ( Power Driven ) includes all type of travelling jib cranes, such as
truck mounted, crawler mounted, locomotive crane on rails.
Figure3.5: hydraulic Mobile crane
Figure3.6: Truck mounted heavy duty crane
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CHAPTER 4
TYPES OF MOTIONS OF JIB CRANES
Jib crane have the following motions:
1. Hoisting motion
2. Derricking or luffing motion
3. Slewing motion
4. Long travel motion
4.1 Hoisting motion:
It is used to lift or lower the load. This is usually achieved by steel wire ropes
being affixed to a crane hook or a grab hanging from the outer end of the jib.
Figure4.1: Hoist of the crane
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4.2 Derricking or Luffing motion:
It is imparted to the inclined member or the jib to move in a vertical plane so that
the angle of the jib may be changed in order to bring the load line nearer to or further off
from the centre of the crane.
Figure4.2: Luffing motion of the crane
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4.3 Slewing motion:
It is imparted to the whole super structure of the crane including the jib, so that it
can turn about a central pivot shaft w.r.t. the non-revolving parts. This motion enables the
crane to shift the load line to revolve round the crane.
Figure4.3: Slewing motion of the crane
4.4 Long Travel Motion:
It may be required when the whole crane structure has to be shifted to
a distant place along a rail track or along a road.
Figure4.4: Long Travel Motion of the crane
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CHAPTER 5
CRITERIA FOR SELECTING JIB CRANE
When selecting a crane, you will take several important requirements into
consideration: application, manufacturing environment, physical restrictions of facilities,
quality of the crane and long and short- term costs.
APPLICATION — The crane must be suited to specific application. If you want
to stack bags of grain onto pallets, you would have a very different crane than someone
who wanted to lift a wooden board into a routing machine.
When speaking to a crane engineer, we should specify how much the product weighs as
this will determine the safe working load, or SWL, of the crane. They should also find
out where the product want to move , and from where. Also, the duty cycle of the crane is
an important consideration. Will the crane be working 24 hours per day, seven days per
week, or will it work a standard 38-hour week with the occasional overtime? And during
those working hours will it be lifting your product once an hour or five times per minute?
It is important to make sure the engineer has all the details of the needs so that they can
put together a crane that suits unique application.
ENVIRONMENT —The physical environment in which the crane is used will
make a difference as to the materials used in the manufacture of the crane. It should be
specified whether it is used indoors or outdoors. Or whether it is in an a typical
environment that is corrosive or gets to extreme temperatures. Or whether it is going into
a sterile environment such a food manufacturing. All of these elements will be important
in designing your crane
FACILITIES — When determining the type of crane and how it will be
installed, it must take into consideration the limitations of the facilities. If it is a roof or
wall mounted crane, you must make sure the building is suitable to bear the loads; if you
are looking at a freestanding crane, the floor must be similarly assessed.
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Although you will only have to do it once, crane installation should also be taken
into consideration. If you have to close down your factory for several days while
someone installs a crane, you will lose a significant amount of working hours and
therefore finished products.
Once the type of crane is determined, then manufacturing needs should be taken
into consideration. And the crane must suit your current production line. The crane might
need it to move things around bends. All of these needs must be taken into account when
selecting a crane.
QUALITY — The jib crane must be able to handle everything in terms of
lifespan and duty cycle. Some additional points that are taken into consideration are the
consistency of the material used in the construction of the crane, the in-house quality
control of the manufacturer, and the testing process.
A high-quality product will last longer than a low-quality product. If you simply
purchase the cheapest crane on the market, you might end up with higher long-term costs.
COST — The price of the crane is one important factor. It must also add in the
cost of installation, maintenance, and future needs. As mentioned before, every hour your
factory is closed down for installation is an hour that can’t be spent manufacturing your
product. Then it is even required to pay for extra labour if the installation requires special
tools or welding.
DESIGN — Since a numerous designs are available for the jib cranes, it is much
relevant to select jib cranes according to specific applications. The design may vary with
types of jib, methods of mounting, modes of motion or rotations etc.
TYPES — The general types of jib cranes available are: floor mounted type,
wall mounted type, portable type etc.
ACCOMMODATING THE FACILITIES — The jib crane should suite for the
existing facilities in the work area. So the type, dimensions, size of jib crane should be
suited for the available work space.
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CHAPTER 6
PORTABLE JIB CRANE
The desired jib crane is portable one with long travel motion. The lifting operation
is powered by an electric motor. Rope and pulley arrangement is used to lift the load,
which is powered by the motor. The designed capacity is 400 kg.
6.1 COMPONENTS
The various components of the jib crane are: jib and frame (mild steel), electric
motor (250 W), worm gear set, winding drum, pulleys, wheels, rope, hook, and forward
and reverse switch.
6.1.1 Jib and Frame
The main components of jib crane are frame and jib. The frame includes the base
of the crane and the vertical column which is connected to the base. The jib is an inbuilt
portion of the column. The material of the frame should be tough enough to withstand the
normal shock load and high bending stresses produced during the loading and
transporting. The material of the frame selected was mild steel. The mild steel holds the
required properties and it is easily available and also cost effective.
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Figure 6.1 frame
The jib is the horizontal arm which is connected to the vertical column by
welding. The jib, vertical column and the base together withstand the bending stress
produced by the load. The design of the jib is done such that the stress induced will be
almost equal throughout the jib span.
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6.1.2 Electric Motor
Electric motor is the power source for loading operation. 240 V Single phase, AC
motor of power rating 250 W is selected for the requirements.
Figure 6.2 electric motor
There is a forward and reverse switch for controlling the motor in both directions.
The motor is connected to the winding drum through gear set.
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6.1.3 Gear Set
The gear set is used to get the reduced speed to the rope drum from
the electric motor. The reduced speed is used for lifting the objects slowly.
Figure 6.3 Gear set
The gear set is having a gear ratio of 320.This gear ratio is obtained by two worm
gear sets of gear ratios 16 and 20.worm gear is selected because it is non-return type.
Major problems with the worm gear are less efficiency and high noise.
6.1.4 Winding Drum
The function of drum is to wind the rope during loading. The winding drum
should withstand the load torque and the bending moment acted upon it. Material of drum
is mild steel .the drum is connected to the gear shaft in one side and opposite side is
connected to the frame through ball bearing.
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6.1.5 Rope
Figure 6.4 Rope
The function of rope is to transmit the rotary motion of drum to the linear vertical
motion of the hoist. The load in the rope is completely tensile. High contact stress will be
induced during the winding on drum and pulley. The selected material of rope is wire
steel. The diameter of the rope is 0.8mm.
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6.1.6 Pulley
Figure 6.5 Pulley
The pulley acts as a guide way for the movement of the rope. The material of the
pulley is sand cast iron. The outer diameter is 10cm and the inner diameter is 1.5cm. Here
totally four pulleys are used.
6.1.7 Wheels
Wheels are attached to the base of the crane for mobility of the jib crane. Here
totally four wheels are used. The front wheels are fixed type and back wheels are
revolving type. Since the crane is moved by pushing from the rear side, the revolving
type wheels make the steering easier. Each wheel is having a capacity to carry 200 kg.
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6.1.8 Hook
Figure 6.6 Hook
Hook is used to hold the materials to be lifted. The material of the hook is forged
iron. The capacity of the specific hook is 1 tonne.
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CHAPTER 7
DESIGN OF JIB CRANE
Figure7.1: stress analysis of the frame
The design load of the jib crane is decided as 400 kg. So the aim is to design the
jib, frame and other components to withstand the stresses due to the loading and the
power requirements for lifting the load properly. Manual calculation and stress analysis
using solid works 2011 are used for designing the components.
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7.1 Jib and Frame
The material of the frame should be tough enough to withstand the normal shock
load and high bending stresses produced during the loading and transporting. The
material of the frame selected was mild steel. The mild steel holds the required properties
The yield point stress is 240 Mpa and the allowable stress is ⁄ , where n is the
factor of safety. The F.O.S can be 2.5 to 3 for MS in normal shock condition. Then the
allowable stress will be 80 to 96 Mpa.
The load is acting upon the frame is such a way that the hook transmit the load to the
rope, then from rope to the jib, then to the vertical portion and finally to the base of the
crane. The load is acting on the jib at the end of it, which produces a bending moment in
the jib. The moment will be maximum at the farthest point from the load, which is at the
rear end of jib and at the vertical column. From the elementary mechanics we have
= ×y/I
Where,
is the maximum bending moment induced duo to the force.
The perpendicular distance is the smallest distance between the vertical
column and the point at which the load is acting. This distance was
initially decided as 65 cm.
is the maximum stress induced in the material
y is the distance from the centroid to the extreme point of the jib-cross
section.
And, I is the moment of area of the section
Now,
= 400×9.8×0.65
= 2550Nm
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Various section were studied for the designing of the jib and among them, varying
rectangular section were find suit for the jib and square pipe section were selected for the
vertical column and the base
The stress will be maximum at the column. The stress induced in various section
were calculated and the stress induced in the column with a section of 3 × 3 inch pipe of
thickness 4mm were calculated as,
= ⁄
Induced stress in the vertical column was found as72 Mpa in tension and 82 Mpa
in compression, hence it found to be safe. Hence 3 × 3 inch pipe of thickness 4mm were
selected for fabrication and since the stress in the jib will be less than that of the column,
the same section is selected for the jib and the construction of the jib is such that two
halves of pipe section is arranged conically and inter connected them by welding with
small rods as shown in figure.
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Figure 7.2: stress distribution in the jib and column
The figure shows the stress distribution in the jib and column. The values are in
Pascal. The maximum stress shown by the software solid works is in the range 70 to 80
Mpa which is nearer to the value got in manual calculations. The stress in the jib is
almost uniformly distributed throughout, but less than the stress in the column. It is to
compensate the stress concentration in welding portion as it is neglected in the
calculations.
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Calculation of Power
The operation speed is an important factor in calculating the power, the load should be
lifted and placed slowly and a maximum speed of 1 cm/s is allowable. So, power
requirement were calculated as,
P = load ×velocity/η
Where,
P = power (W)
η = overall efficiency of system
Since non return type worm gear is used, the efficiency will be less than 50 %. It is
assumed to be as 40 %, then
P = 400 × 9.8 × 0.01/0.4
= 98 W
Hence 0.25 hp motor is sufficient (185 W) but the selected motor has a capacity of
250 W.
The end-load will induce tension in rope, here the loop type rope and pulley
arrangement reduces the load in to half of the actual load, so the tension on the rope will
be half of the weight to be loaded.
The rope tension will produce a turning moment on the winding drum
T = F × 0.5D
Where,
T = the torque (Nm)
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F = the tension in rope = load × 0.5 (N)
D = mean diameter of the winding drum and winded rope (m)
The diameter is initially assumed to be 7 cm, then,
T = 200 × 9.8 × 0.5 × 0.7
= 168 Nm
Since the motor speed and power are constant, the gear ratio can be varied so as to
get the required torque in the winding drum, the input torque to the drum should
overcome the torque induced by the load. The required minimum speed of the drum is
found as,
N =
=
= 5.5 rpm
This speed will meet the torque requirements but the speed of operation found to
be high, hence the drum speed is selected as 4.5 rpm. The average o/p velocity of the
hook was calculated as 0.82 cm/s.
7.2 Gears
The gear ratio is 320, which can’t be obtained by using one gear set. Here two worm gear
sets are used to get required gear ratio of 320. The individual gear sets of gear ratio of 16
and 20 can give a total ratio of 320. The gears should design to withstand the contact
stress as well as the bending stress. The induced contact stress and bending stress can be
calculated by the equations,
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√
[ ]
[ ] ⁄
Where,
= induced contact stress in Mpa.
= induced bending stress in Mpa
= number of teeth in the wheel.
= form factor, taken it as 11.
= center distance =0.5 mx (q + z) in mm.
[ ] = design torque on wheel in Nmm.
= the form factor.
= axial module in mm.
The selection gear started with the known value of[ ] and all other values were
assumed initially. The values of and were checked with different configurations of
gears and finally reached configuration only is describing here
Gear set 1
Taking material as carbon steel, = 2.5 and = 32 and i = 16,
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√
[ ⁄ ]
= 231 Mpa
The design contact stress for the material carbon steel-[ ] is 875 Mpa, so <
[ ], hence the design is safe. Now checking for the bending stress,
[ ⁄ ] ⁄
= 8.1 Mpa
This is very less than the design stress
Gear set 2
Taking material as C-14, = 2.5 and = 40 and i = 20,
√
[ ⁄ ]
= 424 Mpa
The design contact stress for the material carbon steel-[ ] is 875 Mpa, so <
[ ], hence the design is safe. Now checking for the bending stress,
[ ⁄ ] ⁄
= 124 Mpa
The design bending stress for the material C-14 steel-[ ] is 130 Mpa, so < [ ],
hence the design is safe.
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7.3 Winding drum
The winding drum can be considered as a simply supported shaft with both
torsional and bending moments acting on it since the bearing is small in width.
√
√
Where,
= Equalant torque in Nm,
= Equalant bending moment in Nm,
= combined shock and fatigue factor for bending(taken as 2)
= combined shock and fatigue factor for torsion(taken as 1.5)
M = Bending moment in Nm =
= tension in the rope in N
= length of the drum in m ,it is teken as 30 cm.
M
= 150 Nm
T = Torque in Nm
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Then,
√
= 391Nm
(√ )
= 345 Nm
Let,
= the diameter of shaft according ti equalant torque
= the diameter of shaft according ti equalant bending
√
= √
= 3.6 cm
√
= √
= 3.5
From the above two values higher value is to be selected,the actual diameter is taken as 4
cm.
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CHAPTER 8
ADVANTAGES
It can be used in a massive number of areas from vehicle garage to dockyards
,construction site to ware houses
They may be even present in smaller version on the back of lorries for loading
and unloading
Jib cranes are suitable for most places due to the fact that they take up minimal
They take up minimal space but primarily they present a much quicker and safer
way lifting objects
Less personnel injuries
It can save expenditure by allowing the job to be finished quicker and by reducing
time off for accidents and all the implications that may arise from them
So together with the large variety of possibilities and accessories offered, the jib
crane is a hugely adaptable lifting piece of equipment ,suitable for many lifting
and placing application in the majority of areas
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DISADVANTAGES
It is designed for positioning a work piece or total ,rather than for moving a
product along in the work flow like an overhead crane
It is also unsuitable to use when there is a need for precise locating of heavy loads
,a large area of hook coverage or frequent use for heavy loads
The hook coverage is limited to the boom length (typically a maximum of
20ft).the hook operates along a boom which rotates about a fixed point
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CHAPTER 9
WORKING PRINCIPLE
The whole vertical column and jib was assembled to the base, which has four
wheels ,back wheels are turning type to move the crane anywhere. The crane hook is
made to go up or down with help of motor , gear, winding drum which is mounted at
the rear end of the crane and the rope. The motor is controlled through the F/R switch
provided
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CHAPTER 10
CONCLUSIONS
The difference between jib cranes and other kinds of crane is that a jib crane is a
free standing device that usually sits on its own pedestal. These cranes look and function
like the mobile cranes seen at construction sites and elsewhere. They have a motor
usually contained in a base and a long arm that takes the hook over the object to be lifted.
As on mobile cranes the arm can be moved into position to pick up an object then moved
again to transfer it to a location. Jib cranes can either be manually operated or motorized
depending the weight of the loads lifted.
The biggest advantage to using a jib crane is that no overhead structure is
required. This means that no costly engineering work may be needed. Also a jib crane
can be transferred from one location to another with much engineering or construction
work. It can simply be moved via a forklift or other such device. The can be used outside
without a gantry. This makes it ideal for loading or unloading trucks. Such cranes will
also be quite a bit cheaper than overhead cranes or gantry cranes. They will be cheaper
because no structure will be needed for them. No complex structure of machinery will be
required either.
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RECOMMENDATIONS
Even though the designed jib crane is of portable and motorized, this type of jib
cranes have some limitations based on the situations and working environment.The
biggest drawback is that they can take up quite a bit of floor space in a factory or
workshop. This can be an issue in a facility that requires quite a bit of machinery.
Another challenge is that the loads lifted by jibs can be quite limited. It may not lift large
amounts of tonnage. This particularly designed jib crane is able to lift loads upto 400 kg.
The heights that this crane reaches is also very limited, it usually can’t lift objects more
than a few feet off the door. This can limit the usefulness of the jib crane in repair and
manufacturing work. This type of jib crane cannot be used to transfer objects around a
factory or facility the way overhead cranes can. This can limit their use and require the
use of other machines such as forklift. Also a 3600
jib rotation is recommended for the
efficient lifting operation.
It would probably be best to use these types of jib cranes in smaller facilities
where only limited lifting would be required. An example of this would be a garage
where mechanics need to lift engines out of cars. Other locations where they might be of
use include small machine shops, farms, boat yards and smaller factories.
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REFERENCES
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3. Baker J. “Cranes in Need of Change”, Engineering, v. 211, n. 3, p. 298. 1999.
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